Composite multi-wave compression spring

A method of making a multi-wave compression spring comprising:

• forming a generally helical groove in a mold, said groove having a plurality of turns around a longitudinal axis of said mold, each said turn of said groove having a plurality of waves including successive crests and troughs, each said crest and each said trough being aligned with a trough and a crest, respectively, in an adjacent turn of said groove;
• inserting a ribbon of graphite fibers in a resin matrix into said groove;
• setting said ribbon by subjecting said mold and ribbon to pressure, vacuum and heat for a specified length of time by inserting said mold and ribbon into a sleeve and closing open ends of said sleeve with said mold and ribbon therein;
• and
• separating said set ribbon from said mold.

A method of making a multi-wave compression spring comprising:

• forming a generally helical groove in a mold, said groove having a plurality of turns around a longitudinal axis of said mold, each said turn of said groove having a plurality of waves including successive crests and troughs, each said crest and each said trough being aligned with a trough and a crest, respectively, in an adjacent turn of said groove:
• inserting a ribbon of graphite fibers in a resin matrix into said groove;
• setting said ribbon;
• separating said set ribbon from said mold;
• compressing said set ribbon after it has been separated from said mold;
• and
• sealing regions of contact between said aligned crests and troughs in said adjacent turns of said ribbon to inhibit contaminants from interfering with said contact regions.

A method of making a multi-wave compression spring comprising:

• forming a generally helical groove in a mold, said groove having a plurality of turns around a longitudinal axis of said mold, each said turn of said groove having a plurality of waves including successive crests and troughs, each said crest and each said trough being aligned with a trough and a crest, respectively, in an adjacent turn of said groove;
• inserting a ribbon of graphite fibers in a resin matrix into said groove;
• setting said ribbon;
• separating said set ribbon from said mold;
• binding said aligned crests and troughs in said adjacent turns of said ribbon together.